GB2055863A - Production of copolymers of propylene and but-1-ene - Google Patents

Description

1 GB 2 055 863 A 1

SPECIFICATION Production of copolymers of propylene and but-1 -aria

The invention concerns the production of copolymers of propylene and but1 -ene. The copolymers produced by the process of the present invention are suitable for various uses in the field of thermoplastic materials; they can also be used in the production of heat- sealable films. In our prior 5 copending application No. is described the preparation of copolymers ofproDylene and but-1 - ene in which the proportion by weight of units derived from but-1 -ene, this proportion being denoted by the symbol (Bu), is from 10 to 40% and the structure of which is such that the proportion of PRE of isolated ethyl branches with respect to the total amount of the ethyl branches of the copolymer is at least equal to the square of the proportion of links derived from propylene [P] which are contained in the 10 copolymers. In the Examples of that application, the copolymers are prepared by the copolymerisation of propylene and but-1 -ene in a liquid diluent and in the presence of a catalytic system comprising a solid compound based on titanium trichlorid and one or more organo-metallic compounds of one or more metals of groups 11 and Ill of the Pe ' riodic Table of elements.

In order to produce copolymers of a structure such that the proportion of PRE is at least equal to 15 [PM it is necessary that the ratio between the amounts of propylene and but-1 -ene contained in the polymerisation medium be maintained at a substantially constant value throughout the polymerisation operation. The above-mentioned ratio, which is determined experimentally, is selected according to the but-1 -ene content of the copolymer to be produced and according to the catalytic system used.

Preferably, the ratio between the amounts of propylene and but-1 -ene is maintained substantially 20 constant during the polymerisation step by means of an apparatus comprising an analyser for measuring the ratio between the concentrations in respect of propylene and but-1 -ene in the polymerisation reation vessel and means for introducing propylene and but1 -ene into the reaction vessel, the said means being controlled in dependence on one another by the analyser.

The resulting copolymers are suitable for various uses, particularly for the production of heat- 25 sealable films comprising a film of thermoplastic material such as isotactic polypropylene, which is coated on one face with at least one layer of the said copolymer. The polypropylene film, which is usually from 5 microns to 1 mm in thickness and in most cases from 10 to 100 microns in thickness, can be produced by any known means, for example extrusion. Such heat- sealable films must be capable of being heat-treated at fairly low temperatures, say 11 51C or if possible lower. It is also necessary for 30 the heat seal to afford substantial mechanical strength as soon as it is formed, without the necessity of allowing the heat-sealed film to cool completely: this latter quality, which is referred to as the hot strength of the heat seal or weld, is expressed by two temperatures which define a region within which the strength of the heat-sealed joint is sufficient.

Copolymers containing more than 20% by weight of units derived from but-1 -ene are particularly 35 suitable for making heat-sealable films, because they provide the films with both fairly low heat-sealing temperatures of around 11 50C and wide ranges in respect of the hot strength of the heat-sealed join.

It has now been found that it is Possible to produce copolymers of propylene and but-1 -ene that comply with the above-mentioned criteria by using an improved process for the direct polymerisation of the monomers in the gaseous state. This process has the advantage of providing the copolymers directly, without their having to be separated from a liquid polymerisation diluent. In addition, it has surprisingly been found that the copolymers prepared by this process, and more particularly copolymers containing not more than 20% by weight of units derived from but-1 -ene, have a structure that is different from the structure that could have been forecast by theoretical considerations, and also properties that are even better; in particular, it is possible for such copolymers to be used for the 45 production of heat-sealable films whose sealing temperature is lowered to about 1 001C.

In accordance with the present invention, copolymers of propylene and but1 -ene in which (Bu) is from 10 to 40% and preferably from 20 to 35%, and "PRU at least equal to [p12 where (Bu), [P] and ---PRE-are as defined above, are produced by bringing a gaseous mixture of propylene and but-1 -ene into contact, in the absence of liquid diluent, with a catalytic system that is stereospecific in the polymerisation of propylene alone and that comprises a solid compound based on titanium trichloride and one or more organo-metallic compounds of one or more metals of group 11 and/or Ill of the Periodic Table of elements.

The so--lja tfitanium-trichloride-based compounds that can be used in the production of the copolymers according to the invention are solid compounds of titanium belonging to stereospecific 55 catalytic systems used in the production of isotactic polypropylene. Such compounds are generally produced by the reduction of titanium tetrachloride by means of hydrogen, aluminium, an aluminium hydride or an organo-aluminium compound such as an alkylaluminium chloride. Generally, the preparation of such titanium compounds includes or is followed by a treatment of such compounds at a temperature of less than 1 6WC in order to produce the titanium trichloride in the y-crystallographic 60 form. Advantageously, the titanium compounds are prepared by the reduction of the titanium tetrachloride by means of an organo-aluminum compound at a temperature of from -10 to 801C and then heating the resulting precipitate in the presence of an excess of titanium tetrachloride at a temperature which may be as high as 11 50C, the operation being carried out in the presence of 2 GB 2 055 863 A 2 an electron donor compound or being associated with a treatment by means of an electrono donor compound or being associated with a treatment by means of an electron donor compound such as an ether of formula R'-0-R" where each of R' and W' is a C2-, alkyl group. Preferably, the solid titanium-chloride-based compound is prepared in accordance with the information disclosed in our prior UK Patent Specification No 1 531 673 or 1 562 679 by the reduction of titanium tetrachloride 5 by means of an organoaluminium compound and then heating the resulting precipitate at a temperature not exceeding 11 51C, the number of moles of titanium tetrachloride used being in excess of at least 20% with respect to the molar amount of organic radicals of the organo-aluminium compound and the preparation operation being carried out in the presence, as an electron donor, of from 2 to 5 moles of an aliphatic ether as defined above per mole of organoa lu mini urn compound. in 10 accordance with this latter method of preparing the solid titaniumtrichioride-based compound, the organo-aluminium compound is mixed, before the reduction of the titanium tetrachloride, with at least 0.3 mole of ether per mole of organo-aluminium compound.

The organo-metallic compound(s) of a metal or metals of group 11 and/or group Ill of the Periodic Table, which is/are used as a co-catalyst, preferably comprise(s) organo- aluminium compounds having the mean formula AMJ,,,,, where R represents a C2-,2 alkyl group, Z represents a hydrogen atom or a halogen such as chlorine or bromine and x is an integer or a fraction of any value from 1 to 3. Preferably, these compounds are dialkylaluminium chlorides having the formula CIAIR, where R is as defined above, more particularly diethylaluminium chloride. These compounds are advantageously used in amounts such that the ratio between the number of atoms of the metal of groups 11 and Ill and the number of titanium atoms is from 1:1 to 50A.

The components of the catalytic system can be used. in different ways.

The solid titanium-trichloride-based compound can be introduced into the polymerisation reaction vessel directly associated with a carrier comprising solid granules or in the form of a prepolymer produced by means of preliminary polymerisation of ethylene, propylene, but-l-ene ora mixture of two or more of such olefins, in the presence of a catalytic system as defined above. For the production of the prepolymer, it is sufficient to polymerise from 20 to 5000 moles of olefins per gram- atom of titanium of the catalytic system; accordingly, the amounts of prepolymer used remain low with respect to the amounts of copolymer finally produced and consequently have little influence on its properties. The prepolymer in which the titanium compound remains included can be directly used in accordance with 30 the invention as the solid titanium compound. Preferably, the prepolymer is prepared in the absence of an inert liquid diluent such as a saturated aliphatic hydrocarbon. However, it may be prepared in the presence of such a diluent from which it is separated before being put to use. Moreover, it may be advantageous for the prepolymer to be subjected, before being used in the process of the invention, to one or more extraction steps by means of a solvent such as an aliphatic hydrocarbon in order to render 35 the granules of the prepolymer porous and to enhance the accessibility of the olefins to the catalytic locations.

The organo-metallic compound(s) of a metal of groups 11 and 111 of the Periodic Table may also be introduced directly into the polymerisation reaction vessel. Such compounds may also be used in the form of a porous carrier that has previously been impregnated with them; in this case, the porous carrier 40 may be formed by solid granules of organic or inorganic nature or it may comprise the prepolymer mentioned in the preceding paragraph.

The polymerisation operation is carried out in the absence of liquid diluent such as liquid propylene, liquid but-1 -ene or a saturated liquid hydrocarbon, by direct contact of a gaseous mixture containing the propylene and the but- 1 -ene with solid particles of the copolymer in the course of formation and with the components of the catalytic system, which are associated with a solid granular carrier or a prepolymer. This operation is advantageously performed in a reaction vessel, which is referred to as a "fluidisation reaction vessel-, by rising circulation of the mixture of monomers in the gaseous state through a fluidised bed of solid particles of the copolymer in the course of formation.

In order to produce a polymer which has the desired fluidity index, polymerisation may be effected 50 in the presence of a chain-growth iimiter, which generally comprises hydrogen introduced into the gaseous polymerisation mixture in a proportion of from 1 to 20% by volume with respect to the olefins present in the mixture.

The speed of rise to be imparted to the gaseous mixture in order to maintain the copolymer in the reaction vessel in a fluidised state is related to the physical parameters of the copolymer and the gaseous mixture. The principal parameters are the size of the particles of the copolymer in the course of formation, their specific gravity and the viscosity and the specific gravity of the gaseous mixture; speeds of rise are usually some decimetres per second.

The temperature in the reaction vessel is maintained at a sufficient level for polymerisation to be rapid, but without being too close to the temperature at which agglomerates that would interfere with c) 0 or stop polymerisation are formed. The temperature may be from 50 to 901C and is preferably from 50 to 701C.

The composition of the gaseous mixture circulating in the polymerisation reaction vessel is selected in accordance with the proportion of but-1 -ene desired in the copolymer. The total pressure in the reaction vessels is so selected as to avoid condensation of the olefins and is generally lower than 40 65 3 GB 2 055 863 A 3 bars. The gaseous mixture is in contact with the catalytic system present in the reaction vessel for only a limited period of time, which is generally measured as seconds. Accordingly, only a fraction of the olefins introduced into the reaction vessel is polymerised there and it is consequently necessary for the gaseous mixture that issues from the reaction vessel to be recycled to it, with make-up olefins to be 5 polymerised. In order to ensure that the gaseous mixture does not entrain particles of the copolymer or the solid compound of the catalytic system to the outlet of the reaction vessel, the reaction vessel may be provided, for example in its upper portion, with a tranquillisation chamber, which is larger in section than the section of the reaction vessel; in the tranquillisation chamber the speed of rise of the gaseous mixture is lower than in the reaction vessel, which permits at least apart of the particles entrained to fall 10 back into the reaction vessel. The particles entrained by the gaseous mixture may also be separated in a cyclone separator and returned to the reaction vessel, preferably into its lower part. As polymerisation of the olefins causes heat to be given off, the heat produced must be removed in order to maintain a constant temperature in the reaction vessel; the heat for this purpose is preferably removed by circulating the gaseous mixture to be recycled through a heat exchanger disposed outside the reaction 15 vessel.

In order to produce copolymers having the above-mentioned characteristics, it is recommended that the ratio between the amounts of propylene and but-1 -ene in the polymerisation medium should be maintained at a substantially constant value throughout the polymerisation step. This condition can be realised by means of an apparatus comprising an analyser for measuring the concentrations in respect 20 of propylene and but-1 -ene in the polymerisation reaction vessel and means for introducing the olefins into the reaction vessel, the said means being controlled in dependence on one another and on the analyser.

The process of the invention can also be carried into effect in two or more fluidised-bed reaction vessels arranged in series. In this case, only a part of the polymerisation operation is carried out in each 25 reaction vessel and the copolymer in the course of formation circulates from the head reaction vessel to the tail reaction vessel. In an alternative form, some reaction vessels may be arranged in parallel so that the copolymer in the course of formation that issues from one reaction vessel is used to supply two or more secondary reaction vessels.

The finished copolymer can be discharged from the reaction vessel in which it is produced by means of different mechanical or pneumatic devices. One discharge apparatus involves providing the lower part of the reaction vessel with a closable orifice that is is in communication with a chamber where the pressure is lower than in the reaction vessel. Opening of the orifice for a given period of time enables the required amount of copolymer to be introduced into the chamber. When the orifice has been closed again, it is then sufficient to connect the chamber with the outside in order to collect the 35 copolymer.

The proportion by weight in the copolymer of units derived from but-1 ene (Bu) is measured by infra-red spectrophotometry on the basis of absorption at the wavelength A = 13.05 p (microns). This measurement operation is performed on a film of copolymerfrom 0.2 to 1 mm in thickness. The value of (Bu) is given by the following relationship:

(Bu) % = 13 optical density at 13.05 p thickness of the film in mm The optical density at 13.05 p is equal to log,, 1J1, 1. being the intensity of the incident light, 1, being the intensity of the light transmitted and log,, being the decimal logarithm.

The n portion [P] is deduced by calculation from the measured value of (Bu).

The proportion---PRE'of isolated ethyl branches is linked to the distribution of the links derived 45 from but-1 -ene in the macromolecular chain of the copolymers. Indeed, the copolymers of propylene and but-1 -ene comprise a chain of carbon atoms on which are fixed hydrogen atoms and methyl radicals resulting from the propylene molecules and ethyl radicals resulting from the but-1 -ene molecules.

When two or more but-1 -ene-derived links follow each other in the macromolecular chain, the 50 branches formed by the corresponding ethyl radicals are referred to as adjacent. In contrast, when a but 1 -ene-derived link is isolated between propylene-derived links, the corresponding ethyl branch, is said to be isolated. The ratio "PRE", which is conveniently measured by analysis of a sample of copolymer by nuclear magnetic resonance of carbon 13, referred to as "NMR 13C11, consequently expresses the proportion, in the macromolecular chains, of links derived from but-l-ene, which are isolated between 55 two propylene links, with respect to the total of links derived from but- 1 -ene. According to theories relating to the mechanism of polymerisation, the expression PRE = [P12 corresponds to random dispersion of the but-1 -ene derived links in the macromolecular chain; it is in accordance with the factual situation observed experimentally by G. Natta et al (Journal of Polymer Science, Volume 51, page 429, 1961) whereby the reaction speeds of propylene and but-1 -ene are substantially independent of the terminal structure of the polymeric chain being grown.

4 GB 2 055 863A Moreover, examination of the copolymers of the invention by the above- mentioned NMR 11C method indicates that the propylene-derived links are part of sequences of isotactic polypropylene, where the methyl branches are consequently oriented in the same manner. However, these sequences are too short to permit the copolymer, in the solid state, to,dispose itself in a properly ordered spatial arrangement. It is observed in fact that the copolymers of the invention have a level of fusi - on enthalpy which is equal to or lowerthan 18 cal/g, said enthalpy being in most cases from 5 to 15 cal/g underthe measuring conditions set forth in Examples 1 to 5.

Fusion enthalpy of the copolymer corresponds to the amount of heat required to melt one gram of the copolymer. The amount of heat required is linked to the spatial arrangement of the polymer as the amount of heatrequired increases in pr6portion as the structure of the polymer is more highly ordered.

Thus, the fusion enthalpy of isotactic polypropylene which has a regular spatial arrangement is at least cal/g. It is therefore possible, by reference to the fusion enthalpy of isotactic polypropylene, to arrive at an appreciation of the regularity of the spatiala arrangement of the copolymers of the invention and consequently the degree of crystallinity thereof. The degree of crystallinity can also be evaluated by X-ray diffraction but the results obtained with this latter method are fairly arbitrary as they vary widely according to the method selected for splitting the diffraction spectrum up into an amorphous region and a crystalline region.

The copolymers prepared in accordance with the invention can be used as thermoplastic materials; in particular they can be used for the production of hollow bodies which enjoy good transparency, by extrusion-blowing.

The copolymers can also be used for the production of heat-sealable films which are formed by a film of thermoplastic material such as isotactic polypropylene, which is covered on one face by at least one layer of said copolymer. The polypropylene film which is usually from 5 microns to 1 mm in thickness and in most cases from 10 to 100 microns in thickness, can be produced by any known means such as extrusion. In order to increase the transparency of the film and improve the mechanical 25 properties thereof, the film is usually subjected to a double drawing operation, in the direction of its width and in the direction of its length, and to a stabilisation operation at a temperature of from 100 to 1500C.

The copolymers can be applied to the film after it has already been formed, for example by means of the extrusion-coating process which comprises extruding a molten copolymer onto the film 30 when it has already been formed. It is also possible to effect co- extrusion of the film and the layer or layers of copolymer; this operation can be effected by means of an extrusion machine in which, on the one hand, the thermoplastic material for forming the film, and, on the other hand, a copolymer, are introduced into a die in a molten state so that the layer of copolymer is disposed on the surface of the film as it is being formed. The assembly is then drawn in the above- mentioned manner.

Using the copolymers of the invention, it is possible to produce heatsealable films in which the copolymer layer or layers are from 0.1 to 10 microns and preferably from 0.5 to 5 microns in thickness, which films can be heat-sealed to themselves in a sealing temperature range which is in the region of from 90 to 1 500C, so that the heat-sealed join or weld which is thus formed enjoys a sufficient level of strength both in the hot and in the cold conditions. It has also been observed that the films which are 40 produced in this way enjoy excellent transparency and a very high degree of resistance to scratching.

The process of the invention is remarkable in several respects. Indeed, it makes it possible directly to produce copolymers of propylene and but-1 -ene in the form of powders, without the necessity, as in the prior art, of separating the copolymer and the liquid diluent in which the copolymer was formed.

Moreover, the fact that the copolymer is produced in the form of a powder comprising granules of 45 uniform size, of the order to 0.5 to 1 mm in diameter, is an appreciable advantage when the copolymer is put into use.

Moreover, as shown by -the Examples, the copolymers which are prepared in accordance with the invention have even better properties which are particularly appreciated in the production of heat sealable films.

Type example of producing a copolymer a) Preparation of a solid compound of trivalent titanium 380 g of titanium tetrachloride, 120 ml of anhydrous n-heptane and 27 g of diisoamyl ether are introduced into a 1 litre stainless steel reaction vessel. The mixture is heated at a temperature of 351C and with agitation, and a mixture of 30 g of diethylaluminium chloride and 70 g of diisoamyl ether dissolved in 180 ml of n-heptane is introduced into the reaction vessel over a period of 4 hours at a regular rate.

The precipitate formed is kept in an agitated condition for one hour at a temperature of 350C and then for two hours at a temperature of 650C. The titanium compound is then washed 5 times by mixing with 500 ml of n-heptane at a temperature of 650C, and decantation. It is preserved in n-heptane, being 60 protected from air and moisture.

4 b) Preparation of a pre-polymer 250 g of a powder of propylene and but-1 - ene copolyer resulting from a previous operation, 5.4 g GB 2 055 863 A 5 (45 mmoles) of diethylaluminium chloride and an amount of the titanium compound prepared in a) above, corresponding to 15 milligram-atoms of titanium, are introduced into a stainless steel reaction vessel provided with a mechanical agitator and a heating means.

In an agitated condition, and with the contents of the reaction vessel being maintained at a temperature of 600C, propylene is introduced at a constant flow rate of 150 g/h over 5 hours. At the beginning of the operation, and one hour and two hours later, 200 NCM3 of hydrogen at each time are also introduced into the reaction vessel. After 5 hours of polymerisation, the result is 740 g of a fluid powder of pre-polymer which is of a rose-violet colour and which is preserved in nitrogen, protected from air and moisture.

c) Polymerisation of the copolymer in a fluidised bed Polymerisation is carried out in a stainless steel fluidised bed reaction vessel which is 15 cm in diameter and which is provided with an adjoining container under pressure, in which the pre-polymer is stored, and another container into which the polymer formed is discharged. Using this reaction vessel, which contains 100 g of the pre-polymer prepared in b) above, a gaseous flow at a temperature of 601 C and at a pressure of 7 bars is introduced, at the bottom of the reaction vessel, the gaseous flow 15 comprising propylene, but-1 -ene and a small amount of hydrogen, circulating at an upward speed of 15 cm/s. When using the copolymer of Example 4, this mixture contains 70% by volume of propylene, 28% by volume of but-1 -ene and 2% by volume of hydrogen.

The fluidisation gas issuing from the reaction vessel is partially cooled in an exchanger and then recycled to the reaction vessel by means of a blower; the composition and pressure of the gases are 20 kept constant by the addition of the monomers in amounts equal to the amounts consumed during the polymerisation step.

The temperature of the fluidised bed is maintained at a constant value by controlling that of the incoming gas.

The reaction vessel is supplied by the introduction of 10 9 of prepolymer, every 30 minutes. After 25

2 hours of polymerisation, about 50 g of the copolymer is removed from the reaction vessel every 10 minutes, which substantially corresponds to the production; in this way, the bed is maintained at a substantially constant height.

Type example of the production of a heat-sealable film A heat-sealable film is produced by means of a co-extrusion machine which is supplied on the one 30 hand with isotactic polypropylene and on the other hand with a copolymer in accordance with the invention. The resulting ifilm comprises a polypropylene film which is about 1.2 mm in thickness and which is covered on each of its faces with a layer of copolymer, which is about 50 microns in thickness.

The coated film is drawn about 5 times in the direction of its width, at a temperature of 11 01C, and then about 10 times in the direction of its length, at a temperature of 1401C. The resulting film is about 25 35 microns in thickness, with the layers of polymer each being about 1 micron in thickness.

The sealing threshold of the film is measured on a sample of film which is 38 mm in width. For this purpose, heat-sealing tests are carried out on the film, by pressing together two samples of film which are disposed transversely between two flat rectangular jaws measuring 20 mm x 50 mm to which a pressure of 1 kg/cM2 is applied. The jaws are heated at different temperatures of from 90 to 1 50C. The 40 cold strength of the heat-sealed join or weld is measured after the heat- sealed film has cooled to 251C and is expressed by the force in grams required to open the heat-sealed join which has been produced in the above-described manner, over a width of 38 mm. The sealing threshold is the heat-sealing temperature in respect of which the cold strength of the heat-sealed join produced is equal to or higher than 300 g/38 mm. 45 The hot strength of the heat-sealed join is measured by means of a metal blade which is curved over onto itself in such a way that when the ends of the blade touch each other, the blade applies an opening force of 45 g. A strip of the film which is 30 mm in width and which is greater in length than the blade is disposed over the blade, on the outside thereof, so that the copolymer layer is disposed on the blade side and the ends of the film strip project beyond the ends of the blade. The blade and the film 50 covering the blade are bent over and the two free ends of the film are pressed between two jaws which are formed with notches, under a pressure of 35kg/cm' at the selected temperature, for a period of one second, while the blade is held under tension. Just before the jaws are opened, the blade is released so that it applies an opening force of 45 g to the heat-sealed join. The sample is admitted as satisfying the hot strength test on the heat-sealed join or weld at the selected temperature when the join comes open 55 over a depthof less than 3 mm. In this way it is possible to determine the temperature ranges within the limits of which the film satisfies the hot strength test on the join. The jaws used measure 10 mm x 200 mm and their surface comprises a succession of contiguous notches which are parallel to the small side of the jaws and whose profile is formed by a right isosceles triangle placed on its long side which measures 1.6 mm. When the jaws are closed, the teeth of the jaws engage into each other. The jaws 60 grip the film transversely over a surface area measuring 10 mm x 30 mm.

The scratch resistance of the film is evaluated in the following manner: a sample of the film which measures 10 cm x 20 cm is folded over onto itself to form a square measuring 10 cm x 10 cm.

GB 2 055 863 A 6.

The square is rubbed vigorously between the hands, 5 times in each direction. The number and depth of the grooves are evaluated visually and the result is noted by comparison as being good, average or poor.

EXAMPLES 1 to 5 and COMPARATIVE EXAMPLES Cl to C.

1. Under conditions set forth in the type example above the copolymers of Examples 1 to 5 are prepared, the contents thereof of units derived from but-1 -ene being set forth in Table 1. The copolymers of comparative examples C, to C6 are also prepared, under the conditions of type Example A of patent application No 79 01123 and certificatio of addition application No 79 19519; the content in respect of units derived from but1 -ene in the copolymers of comparative examples Cl to C6 is set forth in Tablell.

The following parameters are measured on the copolymers:

a) The content by weight of units derived from but-1 -ene (Bu) by infrared absorption, from which the propylene molar content is deduced: [P]; b) Fluidity index under a pressure of 2 bars at 23WC OF22A which is measured in accordance with standard ASTM D 1238; c) Fusion enthalpy, by means of a Perkin-Elmer sweep-type differential microcalorimeter. The enthalpic diagram of a sample of 5 mg of the copolymer is recorded, by heating at a rate of 160c/minute to a temperature of 2000C (the sample is previously subjected to a heat treatment which comprises heating at a gradient of 1 6C/minute to 2000C, holding at that temperature for 20 minutes and then cooling at a gradient of 1 60C/minute to a temperature of 50IC). The recorded surface area is proportional to the 20 enthalpy; d) The proportion (PRE) of isolated ethyl branches with respect to the total of ethyl branches, by nuclear magnetic resonance of carbon 13 by means of a Bruker WH 360 apparatus operating at 90.52 MHz for 13c on a solution of copolymer in orthodichlorobenzene at 1200C with tetramethylsilane as a reference.

The surface area of two peaks is determined, one peak being S, at 42.8 ppm corresponding to the isolated ethyl branches and the other being S2 at 39.7 ppm corresponding to the other ethyl branches.

The ratio PRE is equal to S,AS, + S2)' The ratio PRE is compared to [p12; the expressiuon PRE/M2 which is always at least equal to unity makes it possible to characterise the distribution of the isolated links derived from but-1 -ene, with respect to a theoretical random distribution of such links.

11. Films of heat-sealable polypropylene are prepared from the foregoing copolymers in accordance with the above-described type example. Taking such films, measurements are made in respect of the sealing threshold and the hot strength range of the heat-sealed join, in the manner described above. The results which are set forth in Tables 1 and 11 show that:

- For the copolymers according to the invention, the expression PRE/[P12 is always markedly greater 35 than unity, in particular for the copolymers of Examples 4 and 5 wherein the content by weight of but-1 ene is higher than 25%. In contrast, the expression PRE/[P11 is only slightly higher than unity for the copolymers of comparative examples Cl to C.. This means that, with an equal but-1 -ene content, the links which are derived from but-1 -ene are distributed-in the macromolecular chain of the copolymers prepared in accordance with the invention, in a more dispersed manner than that which could be forecast on the basis of theoretical considerations, whereas the dispersion is substantially closer to theory for the copolymers of comparative examples C, to Cj - The temperature of the sealing threshold decreases with progressively in proportion as the content by weight of but-1 -ene increases whereas that temperature is stabilised at around 11 51C for the copolymers of comparative examples C, to C, in which the but-1 -ene content is equal to or greater than 45 20%. This phenomenon is illustrated in Figure 1 in which curve A represents the variation in the temperature of the sealing threshold of the copolymers of Examples 1 to 5 while curve B shows the variation in that temperature in respect of the copolymers of examples Cl to C6; - The hot strength range of the heat-sea led join increases progressively as the but- 1 -ene content by weight increases, whereas that range is stabilised in the vicinity of 50 to 550C for the copolymers of comparative examples C, to C, in which the but-1 -ene content is equal to or greater than 20%. This phenomenon is illustrated in Figure 2 in which curve C represents the variation in the hot strength range for the heat-sealed join of the copolymers of examples 1 to 5 while curve D shows the variation in that range as measured on copolymers of examples Cl to C,.

In addition, the films which are produced from the copolymers according to the invention have 55 good scratch resistance which is evaluated in the above-described manner, and excellent transparency as measured by means of a "hazemeter" in accordance with standard ASTM D 1003-61 1 7 GB 2 055 863 A 7 TABLE 1

Example 1 2 3 4 5 COPOLYMERS (Bu) % 10.'5 16 23.8 29.4 32.5 IF 2 2aO 0.8 4 3.5 2 3.6 Fusion enthalpy (ca 119) 17.5 16 13 10- 8 [P] 0.92 0.87 0.81 0.76 0.73 [p]2 0.84 0.76 0.66 0.58 0.54 PRE 0A3 OX1 0.77 0.73 0.70' PRE/ [p]2. 1.10, 1.06 1.17 V.25 1.30 FI LM Sealing threshold (,C) 127.5 125 118 107 100 Hot strength of the heat-sealed join:

- range (OC) 125-140 115-145 100-145 90-145 85-145 - d if frence between limits ('C) a 15 30 45 55 60 TABLE 11

Example C,. C, C, C4 C, COPOLYMERS (BU) % 12.5 16.5 20' 25 32 36 IF 2 230 2 3 3 3.5 3 4 Fusion enthalpy 14.3 11 10 8 7 6 (callg) [P] - 0.90 0.87 0.84 0.80 0.74 0.70 [p]2 0.81 0.76 0.705 0.64 0.55 0.49 PRE 0.85 0.84 0.72 0.68 0.59 0.50 PRE/ [p]2 1.05 1.10 1.02 1.06 1.07 1.0 F] LM Sealing threshold (C) 122 118 115 115 116 116 Hot strength of the heat-sealed join:

range (OC) 115-140 100-145 95-145 95-145 93-145 90-145 difference between limits (C) 25 45 50 50 52 55 1 1 1 1 1 1 - 1 __j 8 GB 2 055 863 A 8

Claims (11)

CLAIMS -

1. A process for the production of copolymers of propylene and but-1 -ene in which the proportion by weight of units derived from but-1 -ene is from 10 to 40% and the proportion of isolated ethyl branches with respect to the total amount of the ethyl branches of the copolymer is at least equal to the square of the proportion of units derived from propylene contained in the said copolymers, comprising bringing a gaseous mixture of propylene and but-1 -ene into contact, in the absence of liquid diluent, with a catalytic system that is stereospecific in the polymerisation of propylene alone and that comprises a solid compound based on titanium trichloride and one or more organo-metallic compounds of one or more metals of group 11 and/or group Ill of the Periodic Table of elements.

2. A process as claimed in claim 1 in which the proportion by weight of units derived from butl - 10 ene is from 20 to 35%.

-

3. A process as claimed in claim 1 or 2 in which the ratio between the amounts of propylene and but-1 -ene contained in the polymerisation medium is kept at a constant value during the polymerisation operation by means of an apparatus comprising an analyser for measuring the ratio between the concentrations of propylene and but-1 -ene in the polymerisation medium and means for introducing 1 propylene and but-1 -ene into the polymerisation medium, the said means being controlled in dependence on one another and on the analyser.

4. A process as claimed in any preceding claim in which the solid titanium-trichloride-based compound is produced by the reduction of titanium tetrachloride by means of an organo-aluminium compound at a temperature of from -10 to 800C and then by heating the resulting precipitate, in the 20 presence of an excess of titanium tetrachloride, at a temperature not exceeding 1 1-50C, the said operations being carried out in the presence of, or being associated with treatment by, an electron donor.

5. A process as claimed in claim 4 in which the electron donor is an ether of formula W-O-Rll where each of R' and W' is a C,-, alkyl group.

6. A process as claimed in claim 4 in which the solid titaniumtrichioride-based compound is prepared in the presence of a molar excess of titanium tetrachloride of at least 20% with respect to the.molar amount of organic radicals of the organo-aluminium compound and, as the electron donor, from 2 to 5 moles of allphatic ether per mole of organo- aluminium compound, the organo-aluminium compound being mixed, before the reduction of the titanium tetrachloride, with at least 0.3 mole of the 30 said ether per mole of organo-aluminium compound.

7. A process as claimed in claim 1, 2 or 3 in which the catalyst is used in the form of a prepolymer produced by preliminary polymerisation of from 20 to 5000 moles of ethylene, propylene, but-1 -ene or a mixture of two or more of such olefins per gram-atom of titanium of the catalyst system.

8. A process as claimed in claim 1, 2 or 3, performed by direct contact of a gaseous mixture 35 containing propylene and but-l-ene at a pressure of less than 40 bars and at a temperature of from 50 to 901C with particles of copolymer in the course of formation and with the components of the catalytic system associated with a granular carrier or with a prepolymer, in a fluidisation reaction vessel where the particles of copolymer in the course of formation and those containing the catalytic system are maintained in the fluidized state by a rising flow of the mixture of the monomers in the gaseous state. 40

9. A process as claimed in claim 1, carried out substantially as hereinbefore described in any one of Examples 1 to 5.

10. Copolymers of propylene and but-1 -ene when prepared in accordance with any one of the precedinTclaims.

11. Copolymers as claimed in claim 10 for use in the production of heatsealable films.

Printed for Her Majesty's Stationery Office by the Courier Press, Leamington Spa, 1981. Published by the Patent Office, 25 Southampton Buildings, London, WC2A lAY, from which copies may be obtained.

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